Modular buttress foundation

ABSTRACT

A ground surface cast-in-place foundation assembly adapted to vertically engage a perimeter beam of a level modular housing comprising a buttress assembly that includes a means for seating the perimeter beam, a tubular stanchion having an upper and lower end, an anchor base plate fixedly connected to the lower end of the stanchion and a couple of transverse tabs attached to the intermediate portions of the stanchion; and a flowable and settable foundation material which envelopes at least a portion of the buttress assembly, wherein the foundation material conforms to the shape of a porous fabric container into which it is poured, and it sets with the enveloped portion of the buttress assembly embedded therein.

BACKGROUND OF THE INVENTION

A. Field of the Invention

The present invention generally relates to an apparatus of establishingcast-in-place and on-ground surface foundation, and more particularly toa foundation to support a perimeter joist for the underside ofmanufactured homes at exterior doors and wide openings.

B. Description of the Prior Art

Manufactured homes are transported to a customer's site for a permanentor semi-permanent setup. One way in practice is through cast-in-placeand on-the-ground building foundations wherein the complete building issuspended while vertical supports such as construction piers andstanchions at selected locations in the foundation plan are engaged attheir top ends to an undercarriage of the building and their bottom endsare buried in fabric containers of cementitious slurry until the piersand stanchions become an integral foundation in the solid block ofconcrete conformed to the ground for the leveled dwelling house.

In U.S. Pat. No. 5,664,377, there is a description with reference to itsFIG. 5 of a foundation assembly comprising a fabric container housingslurry that partially embeds a stanchion equipped with a bracket. Inoperation, the stanchion of the foundation is subject to thecast-in-place installation that requires measuring the distance betweenground surface and the joist to cut the stanchion to an optimal adjustedlength using a tube-cutter. The cut stanchion is then suspended inchesabove ground surface as the fabric container is positioned underneathfor pouring a concrete slurry therein in order to obtain a structurallyintegral foundation that conforms to the ground.

Since the introduction of the same product to the market by theapplicant and as the market has grown up there has been a need for animprovement to the perimeter foundation to fit the updated environmentof the manufactured home building. As the perimeters of manufacturedbuilding under the rim joist need to be blocked with walls for a trimmedfinish, an improved buttress foundation system also became necessarywhile maintaining the benefit of the same rigidity as provided by theabove applicant's patent '377,

U.S. Pat. No. 6,347,489 to Marshall, Jr. et al. discloses a storm anchorsystem including foundation column to receive and support housingstructures of various sizes at its top. However, the anchor system isnot an on-ground but an on-board system having its base fastened to aseparate base of the housing structure and recognizes no needs inperimeter blocking.

Thus, the present invention provides a solution to the aesthetical andstructural additions of perimeter blocking to the modular housing aswell as the direct support that can be custom made on-ground withoutadditional works for foundation base.

SUMMARY OF THE INVENTION

When a manufactured housing arrives at the site, the flooring assemblyis typically supported at its underside by horizontal parallel beams orjoists and also vertically supported by foundations that stand firmly onthe ground. Rim or perimeter joists define the outer bottom edges of thehousing which are suspended like the other joists but need anaesthetical consideration in addition to the basic requirements ofsupport with high structural rigidity. If the mobile housing is doublesized, it is made in two subassemblies for a joint set up into onebuilding where mate line blocking supports are necessary. The perimeterand mate line blocking supports have common place where they support notthe undercarriage beams at the interior of the building but theperipheral beams whether they are on mate line in the center orperimeter line, which will be visible from the outside.

The mobile housing buttress foundation of the present invention isadapted to provide a perimeter blocking with an anchor plate uniquelycombined with the ground surface cast-in-place foundation processdeveloped earlier by the applicant with its practice successful in thefield. Thus, the description and specification of the '377 patent areincorporated herein by reference for better general understanding of thepresent invention.

The present invention provides a ground surface cast-in-place foundationassembly adapted to vertically engage a perimeter beam of a levelmodular housing comprising a buttress assembly that includes a means forseating the perimeter beam, a tubular stanchion having an upper andlower end, an anchor base plate fixedly connected to the lower end ofthe stanchion and a couple of transverse tabs attached to theintermediate portions of the stanchion; and a flowable and settablefoundation material like concrete which envelopes at least a portion ofthe buttress assembly, wherein the foundation material conforms to theshape of a porous fabric container into which it is poured, and it setswith the enveloped portion of the buttress assembly embedded therein.For purpose of the invention, flowable and settable foundation materialmeans any material utilized for stabilizing vertical stanchion includingcement, mortar and slurries, which contain such materials.

The buttress foundation of the present invention is placed under thebottom floor structure of the modular housing behind the sidewallthereof where perimeter-blocking supports are required.

Accordingly, the general object of the present invention is to providean improved buttress foundation for modular housing perimeter-blockingsidewalls in speed and rigidity.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a buttress assembly in operationaccording to the present invention.

FIG. 2 is a perspective view of the buttress assembly of FIG. 1 in moredetail.

FIG. 3 is a schematic view of a modular home employing the inventivebuttress assembly and having perimeter foundation.

FIG. 4 is a combination schematic view of a prior art mobile homesupport system with a modular home support system employing theinventive buttress assembly to support the perimeter.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring to FIG. 1, the novel and improved buttress assembly 10 iscomprised of a selected length of tubular stanchion 12 having at its topan L-shaped bracket 11 to abut the perimeter joist 22 at its bottomplane 23 and an inside plane 24. The stanchion 12 has four side wallsand a rectangular cross section. The L-shaped bracket 11 has a verticalflange 14 with a number of apertures through which attaching bolts 15are threaded into the interior side of the joist 22 such that the baseportion of the stanchion 12 is suspended several inches above groundsurface 16.

A base plate 17 is welded to the base portion of the stanchion 12. Onthe bottom of the base plate 17 a number of anchor bolt heads 18 areprotruded downwardly. Alternatively, J-shaped bolts can also replace thestraight bolts 18.

On a wall of the stanchion 12 away from the vertical flange 14 two steeltabs 19 are welded intermediately with a longitudinal distance from eachother to hold a girt 20.

Fabric container 1 is placed beneath the stanchion 12 and while thebottom end of the container 1 resides on the ground surface 16, a rebar2 is inserted into the container 1 and the entrance to container 1 issuitably tied around stanchion 12, concrete slurry 6 is poured intocontainer 1 to its full capacity. The three dimensional shape of thebase plate 17 with anchor heads 18 will also provide an exceptionalholding force in the resulting concrete base 6 of the buttressfoundation 10.

Thus, the buttress foundation 10 has been completed for the overlyingstructure of the perimeter joist 22 upon which the floor assembly 25 andbuilding walls 26 are rested as shown in the drawings. Attached to thebuilding walls 26 covering the joist 22, an exterior siding 27 protectsthe building against elements. As described above, the girt 20 isattached to the stanchion 12 at its steel tabs 19 by the attachingscrews 21 from the exterior side of the girt 20. An elongated board 28is then applied to the girt 20. Then, an elongated strip or trim 29 isattached to the bottom edge of the siding 27 covering the top edge ofthe elongated board 28. The mounting location of the elongated strip ortrim 29 optionally allows a concealed air gap vent formed between thetrim 29 and the elongated board 28.

FIG. 3 shows the manufactured home in two parts each having the junctionbetween the home parts, i.e. the mate line 32 is defined by a couple ofmate line joists 22 and suspended by mate line piers 30. The buttressassemblies 10 with the concrete portion 6 and fabric container 1 providea perimeter support embodiment. The fabric container is formed as anelongated sleeve that is wrapped and installed around the buttressassemblies 10 allowing the concrete portion 6 to form a perimeterfoundation that connects all of the buttress assemblies 10 in a singlepiece of concrete. The elongated fabric sleeve can be stored as a rollso that it can be cut to length on the job site. Also, the elongatedfabric sleeve can be a continuous sleeve having no opening, allowing theopenings to be cut at the job site.

FIG. 4 shows a combined view of a mobile home support juxtaposed on thepresent embodiment, which is a modular housing system. The combined viewprovides a comparison of the prior art mobile home configuration withthe present invention modular housing system.

The mobile home support has four undercarriage I-beams 31 held above theground by a plurality of piers 34. The traditional mobile home would berolled in as a doublewide trailer on a wheeled axle configuration,installed on the pier supports 34 to allow semi permanent support.

On the other hand, the modular house has two parts divided above alongthe ridge of the roof shown in dotted line and below at the mate line32. The junction between the modular home parts, i.e. the mate line 32is defined by a couple of coupled mate line joists 22 supported by mateline piers 30. Buttress assemblies 10 disposed under perimeter joists 22provide perimeter support. Buttress assemblies 10 are shown in blocksupport embodiment that do not form a perimeter allowing connectionbetween the block supports 6.

The modular house has a more detailed assembly process than the priorart mobile home. The pair of elongated sections of the modular house canbe brought to the construction site by a pair of trucks. Preferably, thewidth of each module can fit on a single flatbed truck. The sections ofthe modular house can be placed upon temporary supports by a crane andleveled. The buttress assemblies 10 arrive at the job site fullyassembled and welded including the tubular stanchion 12, L-shapedbracket 11, vertical flange 14, base plate 17, anchor bolt heads 18 or Jshaped bolts, and steel tabs 19. Each of the sections of the modularhouse is joined to the others. Underneath the house the mate line piers34 are attached to mate line joists 33. The improved buttress assembly10 is installed to the perimeter joist so that the tubular stanchion 12having at its top an L-shaped bracket 11 abuts the perimeter joist 22 ata perimeter joist bottom plane 23 and a perimeter joist inside plane 24.The fabric container 1 is unfurled allowing pouring of the concreteportion 6 into the fabric container 1. After the concrete portion 6cures, the modular house temporary support is removed.

The house then receives installation of exterior siding 27 and elongatedboard 28. Later, an appropriate finish such as stucco can be applied tothe board 28 so that when the perimeter of the house receives landscapebackfill, the backfill will cover a portion of the board 28.

In conformance to current technology, it is appreciated that stanchion12, bracket 14, base plate 17, anchor heads 18, girt 20 and bolts 15 and21 of this invention be constructed of iron, steel, cast aluminum orother appropriately rigid material. Fabric container 1 is composed ofany one of the many geo-textile materials well known in the art. Theelongated board 28 of the present invention may be of treated plywood orother water resistant material.

Therefore, while the presently preferred form of the manufacturedhousing buttress foundation has been shown and described, and severalmodifications thereof discussed, persons skilled in this art willreadily appreciate that various additional changes and modifications maybe made without departing from the spirit of the invention, as definedand differentiated by the following claims.

1. A ground surface cast-in-place foundation assembly adapted tovertically engage a perimeter beam of a level modular housingcomprising: a. a buttress assembly having a means for seating theperimeter beam, a tubular stanchion having upper and lower ends, ananchor base plate fixedly connected to the lower end of said stanchionand a couple of transverse tabs attached to the intermediate portions ofthe stanchion between said upper and lower ends; b. a girt havingopposite side edges fastened to said transverse tabs of said buttressassembly for blocking a clearance of said modular housing from theground; and c. a flowable and settable foundation material whichenvelopes at least a portion of said buttress assembly, wherein thefoundation material conforms to the shape of a porous fabric containerinto which said foundation material is poured and it sets with theenveloped portion of said buttress assembly embedded therein.
 2. Thefoundation assembly set forth in claim 1, wherein said anchor plate ofsaid buttress assembly further includes a plurality of anchor headsprotruding downwardly of the bottom surface of said anchor plate.
 3. Thefoundation assembly set forth in claim 1, wherein said seating means isan L-shaped bracket to abut said perimeter beam at its bottom and sideplanes, said bracket having a vertical flange with a number of aperturesthrough which attaching bolts are threaded into the interior side ofsaid perimeter beam, whereby the base portion of said stanchion issuspended above ground surface.
 4. The foundation assembly set forth inclaim 1, wherein each of said stanchion, bracket, base plate, anchorheads, girt and attaching bolts is constructed of iron, steel, castaluminum or other appropriately rigid material.
 5. A modular buttresssystem adapted to engage a perimeter beam of a level modular housingcomprising: a. a plurality of buttress members having a seat for aperimeter beam, a tubular stanchion having upper and lower ends, ananchor base plate fixedly connected to the lower end of said stanchion;b. a girt having opposite side edges fastened to said buttress assembly;and c. a concrete pouring which envelopes at least the anchor base plateof the buttress members, wherein the concrete conforms to the shape of aporous fabric container into which said concrete is poured and sets withthe enveloped portion of said buttress members embedded therein.
 6. Themodular buttress system of claim 5, further comprising a couple oftransverse tabs attached to the intermediate portions of the stanchionbetween said upper and lower ends, wherein a girt has opposite sideedges fastened to said couple of transverse tabs on said buttressassembly.
 7. The modular buttress system of claim 5, wherein said anchorplate of said buttress assembly further includes a plurality of anchorheads protruding downwardly from the bottom surface of said anchorplate.
 8. The modular buttress system of claim 5, wherein said seat isan L-shaped bracket to abut said perimeter beam at its bottom and sideplanes, said bracket having a vertical flange with a number of aperturesthrough which attaching bolts are threaded into the interior side ofsaid perimeter beam, whereby the base portion of said stanchion issuspended above ground surface.
 9. The modular buttress system of claim5, wherein each of said stanchion, bracket, base plate, anchor heads,girt and attaching bolts is constructed of iron, steel, cast aluminum orother appropriately rigid material.
 10. A modular buttress systemadapted to engage a perimeter beam of a level modular housingcomprising: a. a plurality of buttress members having a seat for aperimeter beam, a tubular stanchion having upper and lower ends, and ananchor base plate fixedly connected to the lower end of said stanchion,the plurality of buttress members arranged at intervals affixed to theperimeter beam; b. a girt having opposite side edges fastened to saidbuttress assembly; and c. a concrete pouring which envelopes at leastthe anchor base plate of the buttress members, wherein the concreteconforms to the shape of a porous fabric container formed as an elongatesleeve into which said concrete is poured and sets with the envelopedportion of said buttress members embedded therein, wherein the concretepouring is rebar reinforced at its footing, wherein said concretepouring structurally connects said plurality of buttress members. 11.The modular buttress system of claim 10, further comprising a couple oftransverse tabs attached to the intermediate portions of the stanchionbetween said upper and lower ends, wherein a girt has opposite sideedges fastened to said couple of transverse tabs on said buttressassembly.
 12. The modular buttress system of claim 10, wherein saidanchor plate of said buttress assembly further includes a plurality ofanchor heads protruding downwardly from the bottom surface of saidanchor plate.
 13. The modular buttress system of claim 10, wherein saidseat is an L-shaped bracket to abut said perimeter beam at its bottomand side planes, said bracket having a vertical flange with a number ofapertures through which attaching bolts are threaded into the interiorside of said perimeter beam, whereby the base portion of said stanchionis suspended above ground surface.
 14. The modular buttress system ofclaim 10, wherein each of said stanchion, bracket, base plate, anchorheads, girt and attaching bolts is constructed of iron, steel, castaluminum or other appropriately rigid material.